Protective Packaging and Delivery

ABSTRACT

A system for delivery of fragile payloads involves a structure having an approximately spherical aspect composed of rigid struts and flexible tendons joining ends of struts, the flexible tendons in tension placing the struts in compression, the structure having a hollow interior, and one or more fragile items wrapped in a shock-absorbing bio-degradable material such that no fragile item contacts another, forming a payload bundle, the payload bundle joined by fibrous filaments suspending the payload within the structure. The structure carrying the payload bundle is carried to a destination by an aerial vehicle and dropped from a height to the ground, where the structure rebounds and rolls, dissipating kinetic energy gained in falling, preventing the payload bundle from striking ground surface.

CROSS-REFERENCE TO RELATED DOCUMENTS

The present application claims priority to application No. 202041018365,filed in India on Apr. 29, 2020. All disclosure of the Indian parentapplication is incorporated in the instant application, at least byreference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention is in the field of payload shipping services andpertains particularly to methods and apparatus for packaging fragilepayloads for destination drop from an aerial delivery vehicle.

2. Discussion of the State of the Art

In the art of shipping to a client, shipping fragile products carriescertain risks that must be mitigated in the way the products arehandled, how the products are shipped and how the products are packagedfor shipment. Fragile shipping products are required in most supplychain policies to be handled very carefully to lower the risk of damageor loss. For example, medicines and antitoxins are important fragileproducts for delivery to hospitals and in some cases customerdestinations. These products are often shipped in fragile vials,syringes, or glass containers inside coolers or rectangular cases byground vehicles or by air then ground vehicles because of the specialcare handling required.

The packaging of these products and other fragile products may beconventional and may be shock resistant but only to a degree. Whileproducts may be insured against damage from inadequate handling andpackaging, there still may be an inconvenience to the client includingloss of time. The supply chain may also suffer an aggregate draw onoverall efficiency due to reshipment requirements from the manufacturerand or retailer to the client due to loss of fragile products duringshipment. The supply chain may also suffer from limitations placed ondelivery methods due to product fragility and inadequate packaging.

Therefore, what is clearly needed is a structure and method ofmanufacture and assembly thereof for enclosing fragile products duringtransportation of those products along a supply chain to an enddestination.

BRIEF SUMMARY OF THE INVENTION

In one embodiment of the invention a system for delivery of fragilepayloads is provided, comprising a structure having an approximatelyspherical aspect composed of rigid struts and flexible tendons joiningends of struts, the flexible tendons in tension placing the struts incompression, the structure having a hollow interior, and one or morefragile items wrapped in a shock-absorbing bio-degradable material suchthat no fragile item contacts another, forming a payload bundle, thepayload bundle joined by fibrous filaments suspending the payload withinthe structure. The structure carrying the payload bundle is carried to adestination by an aerial vehicle and dropped from a height to theground, where the structure where the structure rebounds and rolls,dissipating kinetic energy gained in falling, preventing the payloadbundle from striking ground surface.

In one embodiment the structure is assembled from a plurality ofsubstantially planar polygonal elements, each substantially planarpolygonal element comprising crossed, substantially rigid struts withtendons joining strut ends with adjacent nearest strut ends in the samepolygonal element. Also, in one embodiment the plurality ofsubstantially planar polygonal elements is joined together into thestructure by joining apexes of individual substantially planar polygonalelements to apexes of others of the plurality of substantially planarpolygonal elements. In one embodiment the struts are made of elongated,bio-degradable sticks and may be left on the ground or re-purposed afteruse. And in one embodiment the struts are made from rattan or wickercane.

In one embodiment the tendons are made from jute string. Also, in oneembodiment ends of struts are split and the tendons are inserted intothe slit ends of the struts, joining the ends of struts in assembling asubstantially planar polygonal element. In one embodiment tendons arestretched in assembly of the substantially planar polygonal element,placing the tendons in tension and the struts in compression. In oneembodiment the shock-absorbing bio-degradable material is coir formedinto a fabric, and the fabric is wrapped around individual instances offragile items such that no two fragile items in the payload bundlecontact. And in one embodiment the fibrous filaments suspending thepayload are wool string.

In another aspect of the invention a method for delivery of fragilepayloads is provided, comprising assembling a structure having anapproximately spherical aspect composed of rigid struts and flexibletendons joining ends of struts, the flexible tendons in tension placingthe struts in compression, the structure having a hollow interior,wrapping one or more fragile items in a shock-absorbing bio-degradablematerial such that no fragile item contacts another, forming a payloadbundle, suspending the payload bundle by fibrous filaments within thestructure, delivering the structure carrying the payload bundle to adestination by an aerial vehicle, and dropping the structure with thepayload bundle to the ground at the destination.

In one embodiment the method comprises assembling the structure from aplurality of substantially planar polygonal elements, each substantiallyplanar polygonal element comprising crossed, substantially rigid strutswith tendons joining strut ends with adjacent nearest strut ends in thesame polygonal element. Also, in one embodiment the method comprisesjoining the plurality of substantially planar polygonal elementstogether into the structure by joining apexes of individualsubstantially planar polygonal elements to apexes of others of theplurality of substantially planar polygonal elements. In one embodimentthe method comprises making the struts of elongated, bio-degradablesticks that are left on the ground or re-purposed after use. And in oneembodiment the method comprises making the struts from rattan or wickercane.

In one embodiment the method comprises making the tendons from jutestring. Also, in one embodiment the method comprises splitting ends ofstruts and inserting the tendons into the slit ends of the struts,joining the ends of struts in assembling a substantially planarpolygonal element. Also, in one embodiment the method comprisesstretching the tendons in assembly of the substantially planar polygonalelements, placing the tendons in tension and the struts in compression.In one embodiment the method comprises making the shock-absorbingbio-degradable material from coir, by forming the coir into a fabric,and wrapping the fabric around individual instances of fragile itemssuch that no two fragile items in the payload bundle contact. And in oneembodiment the method comprises making the fibrous filaments suspendingthe payload from wool string.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a tensegrity structure according to anembodiment of the invention.

FIG. 2 is an overhead view of a wrapped payload according to anembodiment of the invention.

FIG. 3 is view of the structure of FIG. 1 carry a payload as shown inFIG. 2.

FIG. 4 is structural diagram depicting an architecture for a basicplanar tensegrity element in an embodiment of the invention.

FIG. 5 is a plan view of a tensegrity element according to FIG. 4,showing tendons and struts, and connections in an embodiment of theinvention.

FIG. 6 is a view of ends of struts in an embodiment of the invention.

FIG. 7 is a tensegrity structure carrying a payload in an embodiment ofthe invention, delivered and dropped from an aerial vehicle.

DETAILED DESCRIPTION OF THE INVENTION

The inventor by various embodiments described herein in enabling detailprovides a three-dimensional tensegrity shield structure for protectingfragile payloads from damage which may occur during product shipping andhandling. The present invention is described in enabling detail usingthe following examples, which may describe more than one relevantembodiment falling within the scope of the present invention.

A tensegrity is an apparatus based on a system of isolated componentsunder a state of compression induced by joined elements in a state ofcontinuous tension. The term tensegrity is taken from the phrasetensional integrity. Another term for describing the tensegrity conceptis floating compression. A tensegrity structure is typically made up ofstruts and tendons which are in a state of stable equilibrium because ofthe way the mechanical stress is distributed in the structure. Thestruts are in a state of constant compression and the tendons are in astate of continual tension. No two struts in a tensegrity apparatus areconnected by joints and do not impart any torque to the structure.

It has occurred to the inventor that the physics involved in thetensegrity concept may be leveraged for creating an organic andbiodegradable tensegrity cage. I one unique embodiment a fragile payloadmay be suspended within a tensegrity cage so as not to be directlyaffected by a physical shock event that might otherwise damage thepayload during shipment.

FIG. 1 is a perspective view of a tensegrity structure 100 according toan embodiment of the present invention. Tensegrity structure 100 isadapted in this embodiment as a shock limiting barrier that may be usedto enclose and protect a fragile payload from physical shock that mayoccur during product shipping, more particularly, drop shipping from anunmanned aerial vehicle (UAV). Tensegrity structure 100 is fabricated oflow-cost bio-degradable materials in this example. A plurality of struts101 may be provided in the form of rattan or wicker cane sticks.

In one embodiment, struts 101 are elongated, bio-degradable sticks andmay be left on the ground or re-purposed after use. Tendons are providedto maintain the tension and compression of the structure. Tendons 102 oftensegrity structure 100 may be made of a natural bio-degradable cordlike jute string. A goal of the invention is to fabricatethree-dimensional tensegrity structure 100 from prefabricatedtwo-dimensional planar cells that may be assembled to provide a cage atthe time of shipping a fragile payload. Tensegrity structure 100 is atruncated octahedron tensegrity fabricated from individual hexagonalelementary cells described in more detail later in this specification.

Struts 101 may be partially split at opposing ends to a designated depthto receive tendons 102, which are jute string in one example. Cottonstring 103 may be wrapped about the ends of struts 101 to preventunwanted splitting beyond the designated split length of about twocentimeters.

FIG. 2 is an overhead view of a fragile payload 200 that may besuspended within tensegrity structure 100 during shipment. Payload 200may comprise fragile items (not illustrated) like medicine vialscontaining insulin and syringes shipped to a diabetes patient or to acaretaker of the patient. The fragile payload may be wrapped in ashock-absorbing bio-degradable material 201 like coir. Coir 201 may beprovided in the form of a multiple layered blanket wrapped about thepayload keeping glass from contacting glass inside the wrap due toplacement of the fragile items in different layers of the wrap.

Coir fiber used in this example derives from the fibrous material foundbetween the hard interior shell and the exterior skin of a coconut. Thehigh content of lignin and cellulose in coir renders it one of thestrongest natural fibers available. Moreover, the break point strengthfor coir fibers is perhaps the highest value known for typical naturalfiber. Therefore coir 201 is a bio-degradable, low-cost choice forcushioning a payload. In alternative embodiments there are othercushioning materials than coir that may be used as well.

In this application, coir 201 is wrapped about the payload items keepingthe items isolated from one another in different layers of the wrap.Wool string 202 may be used to tie the wrap, forming a cushioning bundlewith the fragile payload items secure inside the wrap. Referring nowback to FIG. 1, tensegrity structure 100 approximates a sphere in thisexample and has a sphericity value of greater than 0.9. Greatersphericity value provides a more ball-like property that may be desiredif, for example, a tensegrity cage with a payload suspended inside isdropped from a UAV to the ground.

Referring again to FIG. 2, a shipping operator may wrap fragile payloaditems with coir 201 and may tie the wrap off with wool string 202. Theshipping operator may then quickly assemble a tensegrity cage-likestructure 100 from previously created elementary tensegrity cells. Theoperator may suspend the wrapped payload 200 at center of tensegritystructure 100 by tying it to the tensegrity structure in a variety ofdirections with fibrous filaments such as wool string as used to tie offthe coir wrap.

FIG. 3 is a perspective view of tensegrity structure 100 of FIG. 1enclosing payload 200 of FIG. 2 according to an embodiment of thepresent invention. A portion of tensegrity structure 100 is removedaccording to a broken boundary 300 for the purpose of clarity. Payload200 may be suspended within tensegrity structure 100 at proximal centerof the apparatus. Payload 200 is wrapped in wool string 202 and may besuspended by tying the payload to the struts 101 of tensegrity 100according to the directional arrows.

Payload 200 is, in one embodiment, a light-weight payload containingfragile components. The actual weight of payload 200 may have bearing onthe spherical diameter of the tensegrity structure and whether woolstring may be used to suspend the payload within the tensegrity. Animportant function of tensegrity structure 100 is to prevent payload 200from contacting the ground when a UAV drops the tensegrity structurewith the suspended payload. Tensegrity structure 100 may be fabricatedto form a larger spherical footprint or a smaller spherical print for acertain size and weight of a payload like payload 200 that might belarger in volume and heavier or that might be smaller in volume andlighter.

FIG. 4 is a plan view of an architecture for a basic planar tensegrityelementary cell 400. In an embodiment of the invention three-dimensionaltensegrity structures like structure 100 of FIG. 1 may be assembled fromelementary cells. Cell 400 approximates a hexagonal structure, but othershapes are possible, such as square. Elementary cells like elementarycell 400 may be assembled and stored for later access to build atensegrity structure. A tensegrity structure like structure 100 of FIG.1 may be completely assembled from the planar elementary cells when aneed arises to ship a fragile payload like payload 201 of FIG. 2.

Elementary cell 400 in this example has two vertical struts 401 and onehorizontal strut 402. Struts 401 and 402 may be made of wicker cane.Alternative strut materials may be used. Struts 401 and strut 402 mayhave a nominal diameter of about 9 millimeters. Diameter for the strutsmay be as low as 7 millimeters or as high as 10 millimeters (9 mmnominal) for a light-weight tensegrity structure like tensegritystructure 100 of FIG. 1. In other embodiments cells may be larger andheavier, built of heavier materials to carry bigger payloads.

Struts in general may be straightened and may be shaped using knownmanufacturing processes like broaching, for example. Struts may bepassed through a broaching machine after a straightening process toremove knots and excess material helping to form a smooth and relativelyuniform diameter. A uniform diameter for struts 401 and strut 402 isdesired for uniformity in weight distribution and compression state.Jute string tendons are represented in this view by element number 403.

Vertical struts 401 are preferred to be the same length dimension.Horizontal strut 402 is preferred to be slightly longer than struts 401.Typical dimensions for strut length for a tensegrity structure liketensegrity structure 100 of FIG. 1 may be about 19 centimeters forvertical struts 401 and 22 centimeters for horizontal strut 402. Thedistance between struts 401 may be approximately 10 centimeters.Horizontal strut 402 is placed over top of vertical struts 401 at arelative true position centered vertically and horizontally in thisexample.

FIG. 5 is an elevation view of a planar tensegrity elementary cell 500completely assembled and wrapped according to an embodiment of theinvention. Tensegrity elementary cell 500 includes two vertical struts501 spaced apart and a horizontal strut 502 positioned roughly at acenter position over the vertical struts. The ends of struts 501 andstrut 502 are split in this example to a length of about two centimetersto accept jute string tendons 503. As briefly described above, othertwo-dimensional shapes are possible, which provide for a variety ofthree-dimensional shapes as well. For example, a square planar elementmay be used to construct a cubical tensegrity structure, and otherpolygonal shapes as well.

Jute string tendons 503 are tied off at a tie off points 505 at one endof each of the horizontal struts 501 and 502 in this example. Cottonstring wraps 504 are made at each intersect of jute string 503 andstruts 501 and 502. Wraps 104 prevent further splitting of the canematerial and help keep the jute string tendon anchored in the split endsof the struts. Tensegrity elementary cell 500 has a hexagonal profileafter tying and wrapping. The facet length may be about 9 centimetersalong the jute string tendon between strut ends. A tensegrity structurelike tensegrity structure 100 of FIG. 1 may be assembled from aplurality of hexagonal elementary cells like elementary cell 500 in amanner that each hexagonal face of the elementary cell approximates theshape of an octagon and the tensegrity forms a truncated cube, forexample. There may be a variety of way7s that elementary cells may beassembled into three-dimensional structures.

FIG. 6 is a magnified view of unfinished and finished strut ends 601according to an embodiment of the present invention. Strut ends 601 aremagnified in this view and represent the ends of struts 101 of FIG. 1and are prepared for use in building a tensegrity structure likestructure 100 of FIG. 1.

FIG. 6 depicts a strut end 601 with a spit 602 provided that may beapproximately two centimeters long from the end of the strut. Split 602is provided at both ends of the strut. FIG. 6 also depicts a strut 601that is wrapped with cotton string to produce wrap 603. The jute stringtendon may be assumed present in this example though not illustrated.Cotton wraps 603 reduce the likelihood that the split end will splitfarther than intended and provide retention of the jute string withinthe split end. The wrap also adds to the integrity of the joining of thetendon to the end of the strut.

In the creation of elementary structures, when a tendon is joined by hesplit end to a strut, it is stretched toward the u\end of another strutto which the tendon is to be joined, so when the tendon is pulled intothe split end of the next strut, the tendon itself is placed inconsiderable tension. This tensioning process is continued as a tendonis wrapped further around an assembly of struts, so an elementarystructure is created with tension in all the tendons and resultingcompression in all of the struts. In FIG. 6 it is seen that ends ofstruts with tendons joined may be wrapped with, for example, cottonstring or cloth, to finish and stabilize the joint.

Substantially planar elementary structures as shown in FIGS. 5 and 6 maybe joined into a three-dimensional structure to protect a payload byjoining strut ends of one element to joint ends of other elements andtying the ends together with jute or cotton strands. Joined into athree-dimensional polyhedron structure as shown in FIG. 1 a protectivewall is built around a fragile payload.

FIG. 7 is a front elevation view of a UAV 700 dropping tensegritystructure 100 with suspended payload 200 to the ground from some height.The apparent height to the ground level in FIG. 7 is misleading, becausethe structure and the UAV are shown large enough to include detail, andin an actual delivery, the structure carrying the payload may be drippedfrom a considerable height. The height in delivery from which astructure may be dropped is dependent at least in part on theprobability of the structure arriving at a desired place on the ground.

The light weight of fragile payload 200 suspended in tensegritystructure 100 lends to economic delivery of the payload. The fact thattensegrity structure 100 is made of 100 percent biodegradable materialsas is the wrap and string securing fragile payload 200 enables packagingmaterials to be discarded without further treatment. Deliveries may bemade over remote areas or during an emergency where materials used topackage the fragile payload and the tensegrity structure may bediscarded without concern.

UAV 700 may be equipped to grasp the tensegrity structure, fly to adestination, and then release the tensegrity structure with thesuspended payload from an altitude deemed appropriate for accuracy. In ausual circumstance, when the tensegrity structure with a payload isdropped from a quadcopter or any unmanned aerial vehicle, due to theunique construction of the structure, the struts compress upon impact tothe ground and cause the tensegrity to bounce and roll, therebydissipating the kinetic energy, gained in the fall, during the impact.Since tensegrities are extremely flexible and compressible structures,they absorb the shock and prevent the shock from being directlytransferred to the payload.

FIG. 7 shows structure 100 falling the ground and bouncing. Theball-like shape of a tensegrity polyhedron allows it to bounce and roll,which further helps in shock absorption. Since the payload is suspendedin the middle of the tensegrity polyhedron structure, it has minimal tono contact with the ground during impact.

In another circumstance a tensegrity structure might crush on impactover a finite time, and over a finite distance. In this rare instance,the suspension strings keep payload 200 roughly in the center of theapproximately spherical boundaries of tensegrity 100 preventing thepayload from making contact with the ground. Momentum of the tensegritystructure with the payload is relatively low, as the velocity is limitedby the surface area of the structure and the mass is small. In nearlyall instances the structure will bounce and roll, but if crushingoccurs, the payload is slowed and stopped in a controlled decelerationbefore the payload strikes the ground.

In one embodiment a tail, similar to a tail of a kite, may be providedand wrapped with the structure, such that the tail plays out as thestructure falls, and directs the structure to strike the ground at apredetermined point of the structure, where the cushioning effect may bemaximized.

It will be apparent to one with skill in the art that the tensegrityshield system of the invention may be provided using some or all thementioned features and components without departing from the spirit andscope of the present invention. It will also be apparent to the skilledartisan that the embodiments described above are specific examples of asingle broader invention which may have greater scope than any of thesingular descriptions taught. There may be many alterations made in thedescriptions without departing from the spirit and scope of the presentinvention.

1. A system for delivery of fragile payloads, comprising: a three-dimensional structure assembled from planar elements made from rigid struts and flexible tendons joining ends of struts, the flexible tendons in tension, placing the struts in compression, the structure having a hollow interior; and one or more fragile items wrapped in a shock-absorbing bio-degradable material such that no fragile item contacts another, forming a payload bundle, the payload bundle joined by fibrous filaments suspending the payload within the structure; wherein the structure carrying the payload bundle is carried to a destination by an aerial vehicle and dropped from a height to the ground, where the structure rebounds and rolls, dissipating kinetic energy gained in falling, preventing the payload bundle from striking ground surface.
 2. The system of claim 1 wherein the structure is assembled from a plurality of substantially planar polygonal elements, each substantially planar polygonal element comprising crossed, substantially rigid struts with tendons joining strut ends with adjacent nearest strut ends.
 3. The system of claim 2 wherein the plurality of substantially planar polygonal elements is joined together into the structure by joining apexes of individual substantially planar polygonal elements to apexes of others of the plurality of substantially planar polygonal elements.
 4. The system of claim 1 wherein struts are made of elongated, bio-degradable sticks and may be left on the ground or re-purposed after use.
 5. The system of claim 4 wherein the struts are made from rattan or wicker cane.
 6. The system of claim 1 wherein the tendons are made from jute string.
 7. The system of claim 2 wherein ends of struts are split and the tendons are inserted into the slit ends of the struts, joining the ends of struts in assembling a substantially planar polygonal element.
 8. The system of claim 7 wherein tendons are stretched in assembly of substantially planar polygonal element, placing the tendons in tension and the struts in compression.
 9. The system of claim 1 wherein the shock-absorbing bio-degradable material is coir formed into a fabric, and the fabric is wrapped around individual instances of fragile items such that no two fragile items in the payload bundle contact.
 10. The system of claim 1 wherein the fibrous filaments suspending the payload are wool string.
 11. A method for delivery of fragile payloads, comprising: assembling a structure having an approximately spherical aspect composed of rigid struts and flexible tendons joining ends of struts, the flexible tendons in tension placing the struts in compression, the structure having a hollow interior; wrapping one or more fragile items in a shock-absorbing bio-degradable material such that no fragile item contacts another, forming a payload bundle; suspending the payload bundle by fibrous filaments within the structure; delivering the structure carrying the payload bundle to a destination by an aerial vehicle; and dropping the structure with the payload bundle to the ground at the destination.
 12. The method of claim 11 comprising assembling the structure from a plurality of substantially planar polygonal elements, each substantially planar polygonal element comprising crossed, substantially rigid struts with tendons joining strut ends with adjacent nearest strut ends in the same polygonal element.
 13. The method of claim 12 comprising joining the plurality of substantially planar polygonal elements together into the structure by joining apexes of individual substantially planar polygonal elements to apexes of others of the plurality of substantially planar polygonal elements.
 14. The method of claim 11 comprising making the struts of elongated, bio-degradable sticks that are left on the ground or re-purposed after use.
 15. The method of claim 14 comprising making the struts from rattan or wicker cane.
 16. The method of claim 11 comprising making the tendons from jute string.
 17. The method of claim 12 comprising splitting ends of struts and inserting the tendons into the slit ends of the struts, joining the ends of struts in assembling a substantially planar polygonal element.
 18. The method of claim 17 comprising stretching the tendons in assembly of the substantially planar polygonal elements, placing the tendons in tension and the struts in compression.
 19. The method of claim 11 comprising making the shock-absorbing bio-degradable material from coir, forming the coir into a fabric, and wrapping the fabric around individual instances of fragile items such that no two fragile items in the payload bundle contact.
 20. The method of claim 11 comprising making the fibrous filaments suspending the payload from wool string. 